Stator Coil Insertion Guide for Hairpin Winding Alignment

Solution Overview

Problem

The existing methods for manufacturing hairpin winding type stators in drive motors require additional apparatus and processes for aligning and inserting stator coils, increasing initial investment costs and cycle time.

Innovation Solution

An apparatus that includes a support jig with coil guide members and a driving unit, allowing direct insertion of segment type stator coils into the stator core slots by a multi-axis robot, eliminating the need for separate alignment and gripping apparatuses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate dummy core and gripper are used for aligning and inserting stator coils, then alignment precision is improved, but device complexity and initial investment cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the alignment function (previously performed by dummy core) and the insertion function (previously performed by gripper) into a single integrated coil guide member. This coil guide member includes guide passages that both align and insert stator coils simultaneously, eliminating the need for separate apparatuses while maintaining manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coil guide member is designed to perform multiple functions: it guides the stator coils from the winding machine, aligns them in the correct position, and inserts them into the stator core slots. This multi-functional design replaces the specialized dummy core and gripper with a single universal component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If separate dummy core and gripper are used for aligning and inserting stator coils, then alignment precision is improved, but initial investment cost increases

Engineering Contradiction:

Improvealignment precisionVSAvoidinitial investment cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the alignment function (previously performed by dummy core) and the insertion function (previously performed by gripper) into a single integrated coil guide member. This coil guide member includes guide passages that both align and insert stator coils simultaneously, eliminating the need for separate apparatuses while maintaining manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If separate dummy core and gripper are used for aligning and inserting stator coils, then alignment precision is improved, but cycle time increases

Engineering Contradiction:

Improvealignment precisionVSAvoidcycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the alignment function (previously performed by dummy core) and the insertion function (previously performed by gripper) into a single integrated coil guide member. This coil guide member includes guide passages that both align and insert stator coils simultaneously, eliminating the need for separate apparatuses while maintaining manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coil guide member enables continuous operation by allowing the stator coils to be guided and inserted in a single uninterrupted motion. The guide passages maintain continuous contact with the coils throughout the insertion process, eliminating the need for separate alignment and insertion steps that would require stopping or repositioning.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces equipment investment costs, shortens the assembly cycle time, and improves the winding quality of stator coils by enabling direct and precise insertion of stator coils into the stator core slots.

Implementation Method 1

an operation cylinder installed in the base portion and connected to the core loading portion

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

the lower surface of the movable rail plate being formed with cam follower rails in contact with the cam follower protrusions of the coil guide members

Methodology Applied

Scientific EffectCam mechanism: Cam

Implementation Method 3

forming guide passages connected to the slots in an up and down direction

Methodology Applied

Scientific EffectMechanical guidance:

Data Source

PatentUS11469654B2Apparatus for guiding insertion of segment type stator coil

Publication Date: 2022.10.11 HYUNDAI MOTOR CO LTD

AI summary

An apparatus is provided for guiding insertion of segment type stator coils into slots of a stator core where the stator coils are in multiple layers in the radial direction, and the apparatus includes a support jig forming a penetration hole at a central portion and fixedly installed on an upper surface of a frame, a plurality of coil guide members installed in the support jig to move radially back and forth and forming guide passages connected to the slots in an up and down direction, and a driving unit installed to be connected to the coil guide members and configured to apply a back and forth operational force to the coil guide members.